Page 2 - SVC 810 Tankless Troubleshooting Manual; Table of Contents
SVC 810 Tankless Troubleshooting Manual 1 Table of Contents Specifications common to all product lines ................................................................................ 4 Product (Model) History .............................................................................................
Page 3 - Disassembly and Repair – 1
SVC 810 Tankless Troubleshooting Manual 2 Troubleshooting .......................................................................................................................... 40 Troubleshooting Format and Example.....................................................................................
Page 5 - Specifications common to all product lines
SVC 810 Tankless Troubleshooting Manual 4 Specifications common to all product lines Model See specification sheets for current models and specs Purpose Domestic Hot Water (DHW) supply for showers, cleaning and laundry Rated Gas Input (Btu/Hr.) Modulating See specification sheets for current models ...
Page 6 - Second Generation
SVC 810 Tankless Troubleshooting Manual 5 Product (Model) History Implementation Date Models Affected Modification/Upgrade New Parts Board Programming September 2004 RTG42 Initial Tankless Product Launch n/a n/a May 2005 RTG74 Initial Product Launch n/a n/a Dec 2006 RTG74 Gas Valve change; also incl...
Page 8 - Sequence of Operations; Action
SVC 810 Tankless Troubleshooting Manual 7 Sequence of Operations Action Explanation Hot water faucet is open creating a demand Hot water draw initiates water flow thru the machine. Water flows through the Water Flow Sensor Minimum flow rate of .66 gallons per minute. Printed Circuit Board (PCB) sens...
Page 9 - Sensors and Safety; Oxygen Depletion Sensing System Operation
SVC 810 Tankless Troubleshooting Manual 8 Action Explanation (For indoor model only) When the air intake is blocked, or oxygen in a room is not sufficient, the output of the thermocouple that is located in the Oxygen Depletion Sensing Burner (ODS) will change. The PC Board senses this change and con...
Page 10 - How to Reset the Four (4) Hour ODS Timer
SVC 810 Tankless Troubleshooting Manual 9 No 4 Second attempt by the PCB to increase the airflow rate to balance the air-fuel mixture. PCB continues to try to fix the air-fuel mixture my adding airflow. It now adds a visual alarm on the Remote Control by flashing both the red and green indicators. 5...
Page 11 - Heat Exchanger Thermistor; Maintenance Panel Display
SVC 810 Tankless Troubleshooting Manual 10 Heat Exchanger Thermistor The Heat Exchanger Thermistor monitors the temperature of the water inside the heat exchanger. It will activate to Error Code 15 if the water temperature exceeds 207º F for more than 15 seconds; or 230º F for more than 1 second. It...
Page 12 - Clearing the Fault History; When replaci n g the printed circuit boards adjust as follows.
SVC 810 Tankless Troubleshooting Manual 11 Clearing the Fault History 1. Turn the unit OFF. Remove the front cover. Locate the dip switches on the control board. 2. Make sure all the dip switches are OFF (down position). 3. Locate the #1 dip switch and turn it ON; then turn it OFF. 4. Within 5 secon...
Page 13 - How to Check Manifold Gas Pressure
SVC 810 Tankless Troubleshooting Manual 12 operating water flow. b. Push the Adjusting Button on the PC Board. [LH] is displayed on the LED of remote control. c. Hold the Adjusting Button; push the "SW1" button on the PC Board. The current number [01 - 39] is displayed on the LED of remote c...
Page 14 - Program Chip Adjustment; Remove the front cover.
SVC 810 Tankless Troubleshooting Manual 13 53XP 3.46 + fan pressure (max.) 0.55 + fan pressure (min.) 53XN 2.83 + fan pressure (max.) 0.49 + fan pressure (min.) 53DVP 3.01 + fan pressure (max.) 0.37 + fan pressure (min.) 53DVN 2.95 + fan pressure (max.) 0.39 + fan pressure (min.) 74DVP 7.28 + fan pr...
Page 16 - Error Codes
SVC 810 Tankless Troubleshooting Manual 15 1. Turn off remote control. Leave the unit plugged into a 120 VAC power source. 2. Turn off the gas and water shutoff valves. 3. Remove the front cover. 4. Find the DIP Switch #4 located at the top left hand side of the PCB. 5. Change the DIP Switch #4 sett...
Page 19 - Diagnostic Points on Printed Circuit Board
SVC 810 Tankless Troubleshooting Manual 18 Diagnostic Points on Printed Circuit Board Measurement Point Connection Wire Color Normal Value What you are checking? I – J AC 90 – 110V Do you have power to the control board? U W1 – W2 50K Ω – 500K Ω Is the Over Heat Film Wrap OK? BR1 – BK2 DC 2 - 5V (pu...
Page 20 - Thermistor Resistance Chart
SVC 810 Tankless Troubleshooting Manual 19 Q R1 – W2 DC8 – 30V (measured 2 minutes after combustion startup) P 1 – 2 DC8 – 30V (measured 2 minutes after combustion startup) Is the thermo-electromotive force OK? O W1 – W2 Less than 1V DC; Less than 1 Ω Is the air intake switch working? Thermistor Res...
Page 21 - Fan Speed Chart
SVC 810 Tankless Troubleshooting Manual 20 Fan Speed Chart
Page 22 - Wiring Diagram
SVC 810 Tankless Troubleshooting Manual 21 RTG2-42 Wiring Diagram
Page 23 - Printed Circuit Board
SVC 810 Tankless Troubleshooting Manual 22 Printed Circuit Board
Page 24 - Wiring Diagram – RTG 53
SVC 810 Tankless Troubleshooting Manual 23 RTG 53 Wiring Diagram – RTG 53
Page 25 - Printed Circuit Board – RTG 53
SVC 810 Tankless Troubleshooting Manual 24 Printed Circuit Board – RTG 53
Page 35 - Wiring Diagram – RTG 74
SVC 810 Tankless Troubleshooting Manual 34 RTG 74 Wiring Diagram – RTG 74 A wiring diagram is also located on the inside of the front cover panel.
Page 36 - Printed Circuit Board – RTG 74
SVC 810 Tankless Troubleshooting Manual 35 Printed Circuit Board – RTG 74
Page 37 - MIC-180 Printed Circuit Board
SVC 810 Tankless Troubleshooting Manual 36 MIC-180 & EZ Link There are two kinds of communications cables when manifolding multiple tankless units. If only two like units are connected together, we call that EZ Link. This process uses a single 6 foot long cable with four colored wires at each en...
Page 38 - Test Run Mode; Remove the front cover of the manifold controller.
SVC 810 Tankless Troubleshooting Manual 37 Error Code 03 (MIC-180 & EZLink Only) Explanation: Manifold Control Failure. The unit has lost the communications link between itself and the MIC-180; or between the two units with EZLink. At a minimum check the following: 1. Verify the communications c...
Page 39 - MIC 180 Maintenance Mode Table; SW2 Group Number; Maintenance Information Mode
SVC 810 Tankless Troubleshooting Manual 38 4. Press the SW3 button on the main communication PCB to change to trial operation mode. The left two digits of the LED display will indicate the water heater selected and will illuminate continuously. At the same time, the LED lamp on the main communicatio...
Page 40 - nd Generation Flame Rod Chart; y display; Flame Rod 1
SVC 810 Tankless Troubleshooting Manual 39 5. Select the type of maintenance by depressing SW2 (Group Number) and/or SW3 (Item Number) 6. The initial maintenance item is displayed on the two right digits on the display unit flashing between [Maintenance address – E1] and [Maintenance Data – the firs...
Page 41 - Troubleshooting; When measuring; CAUTION; Troubleshooting Format and Example
SVC 810 Tankless Troubleshooting Manual 40 Troubleshooting • When measuring resistance of a part, turn off the electric power and be sure to disconnect the part completely before measuring (from connector or terminal). Resistance checks are performed on the part while it is disconnected from the con...
Page 42 - Unit Will Not Power On
SVC 810 Tankless Troubleshooting Manual 41 Unit Will Not Power On Explanation: Nothing happens when water is flowing through unit. At a minimum check the following in all cases: 1. Make sure unit is connected to proper 3 prong, grounded power supply and circuit breakers are on. 2. Clean cold inlet w...
Page 45 - Error Code 00; after August 2006 do not have a 60 minute timer.); Warning Code 05; Clean air inlet filter.
SVC 810 Tankless Troubleshooting Manual 44 Error Code 00 Explanation: One Hour continuous combustion timer is activated. Unit has a 60 minute time that will shut off the main burner if used in excess of one hour. Cold water will continue to flow thru the unit. (First generation products only – manuf...
Page 50 - Error Code 12; Bleed all air from gas lines.
SVC 810 Tankless Troubleshooting Manual 49 Error Code 12 Explanation: Flame Failure. Unit went to main burner for a period of time; but has since lost flame or the ability to verify the presence of flame. At a minimum check the following in all cases: 1. Bleed all air from gas lines. 2. Ensure appli...
Page 51 - Error Code 13
SVC 810 Tankless Troubleshooting Manual 50 Error Code 13 Explanation: Oxygen Depletion Sensor activated. The unit was not able to resolve an imperfect combustion issue. At a minimum check the following in all cases: 1. Check for lack of fresh combustion air such as in a tight closet. 2. Check mainte...
Page 52 - Error Code 14; Check gas type of unit and ensure it matches gas type being used.
SVC 810 Tankless Troubleshooting Manual 51 g. If within 3 minutes, you get any reading, and then the reading drops below 8 mv, and then goes to Ø, then we have a problem with the ODS, a missing sensor damper or the burner itself. Replace the burner assembly. What is the big different between normal ...
Page 53 - Error Code 15; Check for restrictions in airflow around unit and vent terminal.
SVC 810 Tankless Troubleshooting Manual 52 Error Code 15 Explanation: Boiling Safety Device. The heat exchanger is too hot. At a minimum check the following: 1. Check for restrictions in airflow around unit and vent terminal. 2. Check for a foreign materials in exhaust venting. 3. Back flush the uni...
Page 54 - Error Code 16; Make sure air filter door is properly seated and clean.
SVC 810 Tankless Troubleshooting Manual 53 Error Code 16 Explanation: Outlet water temperature is to hot. The outlet water temperature is above set point on the remote control. The unit cannot resolve the issue with the cold-water by-pass function. Error Code 21 (Indoor Models Only) Explanation: Air...
Page 55 - Error Code 24; Disconnect remote control and retry.; Error Code 29
SVC 810 Tankless Troubleshooting Manual 54 Error Code 24 Explanation: Malfunction of Operational Switch. At a minimum check the following: 1. Disconnect remote control and retry. 2. Verify unit is electrically grounded. Do not use a 2 prong electrical adapter on the power cord. 3. Press MAX (SW2) bu...
Page 56 - Error Code 31
SVC 810 Tankless Troubleshooting Manual 55 Error Code 31 Explanation: Water Inlet Thermistor has malfunctioned. At a minimum check the following if you get Error Codes 31, 32, 33, & 34: 1. Check for scale build up on the inlet filter screen. This scale build up could also happen inside the machi...
Page 57 - Error Code 33
SVC 810 Tankless Troubleshooting Manual 56 Error Code 33 Explanation: Hot Water Outlet Thermistor has malfunctioned. At a minimum check the following if you get Error Codes 31, 32, 33, & 34: 1. Check for scale build up on the inlet filter screen. This scale build up could also happen inside the ...
Page 59 - Error Code 52
SVC 810 Tankless Troubleshooting Manual 58 Error Code 52 Explanation: Proportional Gas Flow Regulator (P.G.F.R.) Valve fault. Check gas inlet solenoid valve wiring harnesses for loose or damage terminals; and connections to the circuit board are tight. Yes No Flame Rod Status (Flame Rod #3 for 74 Se...
Page 60 - Error Code 61; Check Molex connections of the PCB.; Error Code 65; Access maintenance information to determine flow rate.
SVC 810 Tankless Troubleshooting Manual 59 Error Code 61 Explanation: Combustion Fan failure. Fan motor does not work properly. At a minimum check the following: 5. Ensure fan motor will turn freely. Motor will operate with a small amount of restriction. 6. Check there is some volume of air from the...
Page 61 - Error Code 71
SVC 810 Tankless Troubleshooting Manual 60 Error Code 66 (RTG66 Only) Error Code 71 Explanation: Gas Inlet Solenoid Valve (G.I.S.V) fault. Check gas inlet solenoid valve wiring harnesses for loose or damage terminals; and connection K to the circuit board is tight. Error Code 72 Explanation: Flame S...
Page 62 - Error Code 76; Check remote control wiring for loose or damaged connections.; Error Code 79; Check fan motor for presence of moisture of condensation.; Error Code 82; Check for the presence of the program chip installed on the PCB.
SVC 810 Tankless Troubleshooting Manual 61 Error Code 76 Explanation: Communication Fault with Remote Control. At a minimum check the following: 1. Check remote control wiring for loose or damaged connections. 2. Bypass remote control cable by connecting remote control directly to remote control ter...
Page 63 - Error Code 90; Is the entire vent structure clear and clean of any obstructions?
SVC 810 Tankless Troubleshooting Manual 62 5. If the unit does not operate on initial installation or after replacement of the PCB, then the circuit board requires programming with the fuel type and altitude chip. WARNING: When replacing High Altitude Connector, turn off the electric power to water ...
Page 64 - virgin food grade white vinegar
SVC 810 Tankless Troubleshooting Manual 63 Error Code 99 Explanation: Fan Motor is not creating enough ventilation. The venting system passed pre-purge, but has failed during normal operation. At a minimum check the following: 1. Check for blockage of heat exchanger fins 2. Check heat exchanger flap...
Page 65 - Warning Code P1; Generation 7.4 product series
SVC 810 Tankless Troubleshooting Manual 64 Warning Code P1 Explanation: Water flow rate is less than minimum for main burner ignition. The unit must have .66 gallons per minute before the main burner will light or sustain burner. When water flow does not reach minimum flow rate for five seconds the ...
Page 66 - Air Filter Switch; Connection Cold Water Inlet Thermistor
SVC 810 Tankless Troubleshooting Manual 65 2. Air Filter Switch a. Remove the single screw closest to white Molex connector. b. Remove Molex if replacing air filter switch. 3. Water Inlet Solenoid ; Cold Water Connection; Cold Water Inlet Thermistor d. Step 1 and e. Remove four screws on the cold wa...
Page 68 - Fan Assembly; Step 1 and
SVC 810 Tankless Troubleshooting Manual 67 5 Fan Assembly a. Step 1 and b. Clip plastic tie holding Ambient Air Thermistor. c. Disconnect Fan Assembly Molex. d. Loosen wire clip holding the wire bunch in place. e. Remove three screws (one outside bottom; one inside back left; one inside back right).
Page 69 - Proportional Gas Flow Regulator; Step1 and
SVC 810 Tankless Troubleshooting Manual 68 6 Proportional Gas Flow Regulator (Gas Valve) a. Step1 and b. At the gas valve, remove the three retains clips and screws from each of the gas manifold tubes. Note the brass colored tube has a special clip; the silver colored tubes have a different clip. c....
Page 70 - Burner Plate Cover; Step 7 and
SVC 810 Tankless Troubleshooting Manual 69 7. Burner Plate Cover a. On the burner plate cover, remove the two retaining clips and crews from the manifold supply tubes. b. At the gas valve, remove the three retains clips and screws from each of the gas manifold tubes. Note the brass colored tube has ...
Page 71 - Igniter and Igniter Probes
SVC 810 Tankless Troubleshooting Manual 70 8 Igniter and Igniter Probes a. Step 7 and b. Remove the two screws that hold the right hand ceramic igniter probe (black wire) on the burner chassis. c. Remove the two screws that hold the left hand ceramic igniter probe (black wire) on the burner chassis....
Page 72 - Parts; Picture
SVC 810 Tankless Troubleshooting Manual 71 Parts Below are the most common replacement parts. For a complete list of all replacement parts, please see the most current parts catalog. Part Description Picture Water Flow Inlet Valve Cold water inlet valve that measures water temperature and detects fl...
Page 75 - Parts Exploded View for RTG2-42PV and RTG 53PV
SVC 810 Tankless Troubleshooting Manual 74 Parts Exploded View for RTG2-42PV and RTG 53PV Ref # Description 1 Control Board Control Board Fuse (5A) Power Line Fuse (3A) Program Chip 2 Gas Valve 3 Burner Assembly Flame Rod Ignitor Electrode Flame Rod Wire 4 Ignitor Coil 5 Fan Assembly 6 Burner Manifo...
Page 76 - Parts Exploded View for RTG 53X
SVC 810 Tankless Troubleshooting Manual 75 Parts Exploded View for RTG 53X Ref # Description 1 Control Board Control Board Fuse (5A) Power Line Fuse (3A) Program Chip 2 Gas Valve 3 Burner Assembly Flame Rod Flame Rod Wire Igniter Electrode 4 Ignitor Coil 5 Fan Assembly 6 Burner Manifold 7 Gas Inlet ...
Page 77 - Parts Exploded View for RTG 53DV
SVC 810 Tankless Troubleshooting Manual 76 Parts Exploded View for RTG 53DV Ref # Description 1 Control Board Control Board Fuse (5A) Power Line Fuse (3A) Program Chip 2 Gas Valve 3 Burner Assembly Flame Rod Flame Rod Wire Igniter Electrode 4 Ignitor Coil 5 Fan Assembly 6 Burner Manifold 7 Gas Inlet...
Page 78 - Parts Exploded View for RTG 66DV
SVC 810 Tankless Troubleshooting Manual 77 Parts Exploded View for RTG 66DV Ref # Description 1 Control Board Control Board Fuse (5A) Power Line Fuse (3A) Heat Exchanger Thermistor - Yellow Ambient Thermistor - Blue 2 Inlet Thermistor - White 2 Outlet Thermistor - Black Gas Valve - LP 7 Gas Valve - ...
Page 79 - Parts Exploded View for RTG 74PV and GT 199PV
SVC 810 Tankless Troubleshooting Manual 78 Parts Exploded View for RTG 74PV and GT 199PV Ref # Description N/S** Transformer (120v to 100v) 1 st Generation only 1 Control Board Control Board Fuse (5A) Power Line Fuse (3A) Program Chip 2 Gas Valve 3 Burner Assembly Ignitor Electrode Flame Rod Flame R...
Page 80 - Parts Exploded View for RTG 74DV and GT 199DV
SVC 810 Tankless Troubleshooting Manual 79 Parts Exploded View for RTG 74DV and GT 199DV Ref # Description N/S** Transformer (120v to 100v) 1 st Generation only 1 Control Board Control Board Fuse (5A) Power Line Fuse (3A) Program Chip 2 Gas Valve 3 Burner Assembly Ignitor Electrode Flame Rod Flame R...
Page 81 - Parts Exploded View for RTG 74X and GT 199X
SVC 810 Tankless Troubleshooting Manual 80 Parts Exploded View for RTG 74X and GT 199X Ref # Description N/S** Transformer (120v to 100v) 1 st Generation only 1 Control Board Control Board Fuse (5A) Power Line Fuse (3A) Program Chip 2 Gas Valve 3 Burner Assembly Ignitor Electrode Flame Rod Flame Rod...